Single-point supportive monocoque ambulation aid

ABSTRACT

Example ambulation aid apparatus and associated methods of manufacture are disclosed and described herein. An example single-point supportive ambulation aid is formed as an integral part. The integral part of the example ambulation aid is formed to integrate: a body portion formed to support a user; a graspable area integrated with the body portion and providing an area to be gripped by a user; and a foot portion integrated with the body portion and providing a single point of contact with a walking surface to facilitate user movement and support in conjunction with the body portion and graspable area through the integral part.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority to U.S.Non-Provisional application Ser. No. 14/600,721, filed on Jan. 20, 2015,entitled “SINGLE-POINT SUPPORTIVE MONOCOQUE AMBULATION AID”, whichclaims the benefit of priority to U.S. Provisional Patent ApplicationNo. 61/929,779, filed on Jan. 21, 2014, entitled “MONOCOQUE AMBULATIONAID”, each of which is hereby incorporated by reference in its entiretyfor all purposes.

FIELD

The present field of invention relates to ambulation aids, and morespecifically to an ambulation aid formed in monocoque, semi-monocoque,unibody, or other integral construction.

BACKGROUND

A range of ambulation aids have been developed over the many years sincethese devices were first introduced. These devices are used to assistpeople in the act of walking or standing by providing weight bearingand/or balance assistance. Historically, the basic construction methodhas changed little, with the vast majority being constructed of extrudedmetal tubing. A smaller percentage of devices have been constructed ofassembled polyvinyl chloride (PVC) plumbing pipe, hydroformed metal, oroccasionally injection molded polymer parts.

In either case, multiple pieces (e.g., multiple tubes) must be assembledto create a frame on which one or more supports can be provided to aidin user mobility. Such tubular frame-based assemblies are complex tomanufacture and assemble and suffer from multiple joinders and othercontact points. Additionally, the tubular frame creates an undesirableaesthetic. Further, an excessive amount of time and multiple processesmay be required in assembly.

Current construction techniques only offer a limited range ofengineering and design flexibility. This is due to the nature of thematerials used, as well their method of manufacturing and construction.Designs based on tubular materials are limited by factors such as theavailability of stock materials, bend radii of the tubes, how the tubesare joined at intersections, weight of the tubes, strength of the tubes,the overall shape and form of the cylindrical materials, etc.Hydroformed metal construction allows for more design flexibility thantubular materials, but the nature of the hydroforming process and thematerials used are expensive and can quickly place the ambulation aidout of the price range of most users. Injection molded polymerconstruction can offer yet more design flexibility than hydroformedmetal, but the geometry required to make the parts strong enough for useresult in an overly heavy part. In addition to the weight disadvantage,all of the structural ribbing required to make an injection molded solidpolymer part strong enough for use results in a part that is generallyunattractive on at least one side, while all of the cracks and crevicesalso make it difficult to clean.

BRIEF DESCRIPTION OF THE DRAWINGS

A clear conception of the advantages and features constituting thepresent invention, and of the construction and operation of typicalmechanisms provided with the present invention, will become more readilyapparent by referring to the exemplary, and therefore non-limiting,embodiments illustrated in the drawings and photos accompanying andforming a part of this specification, wherein like reference numeralsdesignate the same elements in the several views, and in which:

FIGS. 1-5 illustrate views of an example cane-type ambulation aid.

FIGS. 6-9 illustrate views of an example crutch-type ambulation aid.

FIGS. 10a-d illustrate example handle configurations facilitatingmovement of a handle moveably affixed to a body of an ambulation aid.

FIG. 11 illustrates a flow diagram of an example method to manufacturean ambulation aid.

FIG. 12 illustrates a flow diagram of an example thermoforming processto manufacture an ambulation aid.

FIG. 13 illustrates a flow diagram of an example blow molding process tomanufacture an ambulation aid.

FIG. 14 illustrates a flow diagram of an example rotational moldingprocess to manufacture an ambulation aid.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS Overview and BriefDescription

Before the embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of the components setforth in the following description or illustrated in the drawings. Theinvention is capable of other embodiments and of being practiced orbeing carried out in various ways. Also, it is to be understood that thephraseology and terminology used herein are for the purpose ofdescription and should not be regarded as limiting. The use of“connected,” “including,” and “comprising” and variations thereof in thedescription and the claims is meant to encompass the items listedthereafter and equivalents thereof as well as additional items andequivalents thereof.

Certain examples described and disclosed herein relate to ambulationaids, and more specifically to ambulation aids formed in unibody,unitary, monocoque, and/or semi-monocoque construction for simplifiedmanufacture, durable construction, and user support, as well as morepleasing aesthetics and increased design options. For example, anambulation aid can be constructed to be primarily hollow and made of amolded polymer material, allowing for a lightweight, yet strong,customizable, and economically viable solution. The ambulation aid caninclude a cane- or walking stick-type ambulation aid, a crutch-typeambulation aid, etc. The inventive structure also allows for integratedaccommodations such as hooks, holders, latches, compartments, heightadjustment, and/or the like to be integrated into and/or otherwiseattached to the structure.

In certain examples, an assistive cane, crutch, or other mobility aidcan help redistribute weight from a user's lower leg. The aid canimprove stability by increasing a base of support for the user's leg.The aid can also provide tactile information to the user about theground or other walking surface to help improve balance of the user.Canes are generally lighter than crutches. However, since a canetransfers a user weight load through the user's unsupported side, thecane is unable to offload equal loads from both legs, for example. Incontrast to a cane or crutch, a walker held in front of the userallowing the user to lean on it is more stable due to a greater surfacearea contacting the ground, floor, etc., but walkers are larger and lesswieldy than canes or crutches.

In certain examples, an ambulation aid apparatus is formed to unify aplurality of structural and/or ornamental features into a singleintegral part. For example, a body of the example ambulation aidapparatus may serve as a protective shell with integrated support framewhile also providing a cosmetic exterior for the ambulation aid. Thus,the ambulation aid body provides structural strength and support whilealso providing a cosmetic exterior and/or interior for the apparatus ina single integral part (e.g., using monocoque construction). The body ofthe example ambulation aid may also provide integrated mounting and/orattachment point(s) to attach one or more components/subassemblies tothe body.

Certain examples provide a unibody or monocoque design to lendsimplicity, stability, and improved support to the ambulation aid. Aunibody or monocoque design is a structural approach that supports loadsthrough the ambulation aid's shell or skin, which provides a combinedbody and frame in a single structure (rather than a tubular frameconstructed from a plurality of separate but connected tubes andincluding additional attachments). In certain examples, a monocoque orunibody ambulation aid provides a structural skin or shell designed tobear weight from a user relying on the ambulation aid for movement,stability, and/or other support.

In monocoque construction, for example, a skin or surface is thesupporting structure for the ambulation aid. All or most of the load onthe aid is taken by the surface or skin. Semi-monocoque construction isa hybrid structure in which a surface, skin, or shell is reinforced withrings, ribs, or frames to help carry the stress of a load, for example.In unibody construction, for example, a body is combined with a frame toprovide supporting structure for the ambulation aid. In body on frameconstruction, for example, a skin is wrapped around a structural frameto provide supporting structure for the ambulation aid. In certainexamples, one or more of monocoque, unibody, and body-on-frameconstruction can be combined to create a hybrid ambulatory aidapparatus.

In certain examples, an integral body of an example ambulation aid canbe formed from one or more slabs or sheets of material. For example, theintegral body can be formed from one or more sheets of a polymermaterial. Surface(s) of the integral body can be molded, machined,and/or otherwise formed via a thermoforming, extrusion, and/or otherprocess, for example. As used herein, the terms sheet, slab, and coremay be used interchangeably.

In certain examples, an external contour of an integral body of anexample ambulation aid can embody an outward and interior physicalappearance of the ambulation aid. That is, the integral body can includevarious ornamental features that improve an aesthetic appearance of theambulation aid, for example.

Certain examples provide an apparatus including an ambulation aid bodyformed as an integral part, the integral part formed in monocoqueconstruction to provide support for mobility of a user through theintegral part, the integral part providing a plurality of grippableareas to facilitate user movement and support through the integral part.

In some examples, the ambulation aid body is to be formed as an integralpart via a thermoforming process. In some examples, the ambulation aidbody includes a reinforced, hollow integral part. In some examples, theambulation aid body is to be formed from a polymer material.

In some examples, the plurality of grippable areas include one or moreof a handle, an opening, a top of the ambulation aid body, a side of theambulation aid body. In some examples, the handle is at least one ofmovably affixed to and incorporated into the ambulation aid body. Insome examples, the handle is to be movable with respect to theambulation aid body to adjust a height of the ambulation aid body withrespect to the user.

Certain examples provide a method of forming a monocoque ambulation aid.The example method includes forming, from a supply of moldable material,an ambulation aid body as an integral part in monocoque construction,the ambulation aid body formed in monocoque construction to providesupport for mobility of a user through the integral part, the integralpart providing a plurality of grippable areas to facilitate usermovement and support through the integral part. In some examples, themethod further includes attaching one or more subassemblies to theformed ambulation aid body. In some examples, the ambulation aid bodyincludes one or more connectors to enable the ambulation aid body to befolded.

In some examples, forming includes forming, from a supply of moldablematerial using a thermoforming process, an ambulation aid body. In someexamples, the thermoforming process includes a twin sheet thermoformingprocess. In some examples, forming includes forming, from a supply ofmoldable material using a blow molding process, an ambulation aid body.In some examples, forming further includes reinforcing the ambulationaid body to produce a reinforced, hollow integral part. In someexamples, the supply of moldable material includes a polymer-basedmaterial.

In some examples, the plurality of grippable areas include one or moreof a handle, an opening, a top of the ambulation aid body, a side of theambulation aid body. In some examples, the handle is at least one ofmovably affixed to and incorporated into the ambulation aid body. Insome examples, the handle is to be movable with respect to theambulation aid body to adjust a height of the ambulation aid body withrespect to the user.

Certain examples provide an ambulation aid apparatus. The exampleambulation aid apparatus includes a primary panel formed in monocoqueconstruction to provide support for and assist in mobility of a userthrough the skin of the monocoque primary panel, the primary panelformed to interrelate with one or more subassemblies to provide anintegrated monocoque part to assist in providing support for andimproved mobility of the user through the integrated monocoque part. Insome examples, the primary panel is to be formed via a thermoformingprocess. In some examples, the primary panel includes a reinforced,hollow monocoque part.

In some examples, the one or more subassemblies include one or moregrippable areas including one or more of a handle and an opening withrespect to the ambulation aid apparatus. In some examples, the one ormore subassemblies include at least one of a tread, a skid, a metalliccleat, etc., affixed to the ambulation aid apparatus to facilitatemovement of the ambulation aid apparatus by the user.

For example, a cane-type ambulation aid can be formed by which one ormore portions of the cane (e.g., handle, collar, shaft/body,foot/ferrule, etc.) are formed as one via monocoque, unibody, and/orsimilar construction. Such construction simplifies, unifies, andstrengthens the cane and reduces its cost and likelihood of failure.Similarly, one or more portions of a crutch can be formed as one viamonocoque, unibody, and/or similar construction to simplify, unify, andstrengthen the crutch for a user and reduce cost while enhancingdurability and reliability, for example.

Certain examples provide a single-point supportive ambulation aid formedas an integral part. The integral part of the example ambulation aid isformed to integrate: a body portion formed to support a user; agraspable area integrated with the body portion and providing an area tobe gripped by a user; and a foot portion integrated with the bodyportion and providing a single point of contact with a walking surfaceto facilitate user movement and support in conjunction with the bodyportion and graspable area through the integral part.

A method of forming a single-point supportive ambulation aid as anintegral part. The example method includes providing a supply ofmoldable material; and forming, from the supply of moldable material,the ambulation aid as an integral part. In the example method, theintegral part formed to integrate: a body portion formed to support auser; a graspable area integrated with the body portion and providing anarea to be gripped by a user; and a foot portion integrated with thebody portion and providing a single point of contact with a walkingsurface to facilitate user movement and support in conjunction with thebody portion and graspable area through the integral part.

Example Ambulation Aids

FIGS. 1-5 illustrate views of an example cane-type ambulation aid. Asillustrated in the examples of FIGS. 1-5, while formed from a monocoque,unibody, and/or other similar design, the example cane-style ambulationaid 100 provides an adaptable, adjustable, easy to use and maintainassistant for a user who needs or desires an aid for walking, standing,etc.

As shown in the example of FIG. 1, an example cane-style ambulation aid100 includes a body portion 110 (e.g., a monocoque, unibody,body-on-frame, and/or other construction body), a graspable area 120,and a foot portion 130. For example, the cane-style ambulation aid 100shown in FIG. 1 includes a single body portion 110 to which a foot 130(e.g., a rubber pad, plastic pad, etc.) is attached. A handle and/orother graspable portion 120 protrudes from the body 110 in the exampleapparatus 100. FIG. 1 illustrates a side or profile view of the exampleapparatus 100.

The body 110 of the example ambulation aid 100 shown in FIG. 1 can bemanufactured from a molded material such as a polymer-based materialformed in unibody or monocoque construction (e.g., hollow, foam-filled,etc.) to provide a lightweight, yet strong, and customizable support fora user, such as an elderly user, rehabbing patient, disabled user, obeseuser, etc.

The body 110 can be formed by a variety of manufacturing processesincluding a twin sheet thermoforming process. In certain examples, thebody 110 can include and/or be formed from material includingtransparent, translucent, antimicrobial, bullet resistant, and/or othermaterial. The body 110 can be provided with one or more customizablefinishes (e.g., laminate, co-extruded laminate, paint, plating,texturing, applied graphics, embedded color/finish in base material,etc.), for example.

In certain examples, the body 110 serves as an enclosure, frame,support, and cosmetic exterior for the ambulation aid 100 to provide arigid structure to the aid 100. In some examples, the body 110 mayinclude openings, compartments, attachment points, interlockingconfigurations, etc., to facilitate incorporation and/or otherattachment of accessories, components, and/or other subassemblies withand/or into the body 110. Depending upon size and configuration, one ormore accessories/components/subassemblies can be formed as part of thebody 110, separate from and attached to the body 110, and/or provided bya third party and accommodated by forming openings and/or otherattachment points in the body 110, for example.

The body 110 and associated components are formed from one or moreselected materials. Material selected to form the body 110 and/or othercomponent(s) may be selected based on one or more factors includingstrength (e.g., tensile strength), density (e.g., lightweight), strengthto weight ratio, Young's modulus, weather resistance, antimicrobialproperties, cleaning ability, bullet resistance, formability, finishing,recyclability, tooling costs, design flexibility, manufacturing cost,reproducibility, etc. Material selection may also depend on and/or beinfluenced by aesthetics including color, transparency, translucency,durometer, surface finish, etc.

In certain examples, the body 110 is formed as a single integral part.For example, the body 110 is formed as a single, complete unit. By beingintegrally formed, the body 110 is structurally stronger thanconventional multi-part constructed frames (e.g., traditional canes thatinclude parts that are fastened together). Further, unlike conventionaldevices that include seams between component parts, the example body 110has a substantially seamless appearance. Construction of a mobility aidfrom substantially fewer parts provides benefits for a stable feel andmanufacturing efficiency (e.g., faster throughput due to less assembly,fewer hand touches, etc.), for example. Fewer connected parts and lessplay in their connections results in less rattling and a moresecure/stable body 110, for example. Additionally, by forming the body110 as a single integral part, weather resistance, water resistance,recyclability, etc., is improved.

In certain examples, the body 110 provides support to a user whilelending strength and stability to the user via the body 110 as well asto connected components such as handle 120, foot 130, etc. Further, thebody 110 provides an aesthetically pleasing look by forming part of anornamental appearance of the ambulation aid 100.

The graspable area 120 provides support to a user to grip and hold ontothe aid 100. In certain examples, rather than protruding handles 120,one or more openings in the body panel 110 and/or other grips on or inthe body panel 110 can be provided. In certain examples, the footportion 130 can include a skid, ski, tread, metallic cleat, etc.,instead of or in addition to a foot post, pad, peg, etc., to facilitatestability and movement of the aid 100 while supporting the user.

In some examples, the graspable area 120 can be implemented as a post orpole graspable by a user for support and/or mobility. The graspable area120 can be molded from plastic, die-cast metal, extruded plastic and/ormetal, etc. The graspable area 120 can be integrated into the body 110design. In certain examples, different size mobility aids can beproduced with a fixed and/or movable handle.

In some examples, the graspable area 120 (e.g., a handle) is positionedin a T-slot track (e.g., mounted on or including a T-slot nut or otherconnector that slides in a T-slot track) such that the graspable portion120 slides up and down in the T-slot track (also illustrated, forexample, in FIGS. 2 and 5). The track can be designed into the main body110 geometry, a separate channel (e.g., metal, plastic, other polymer,etc.) can be inserted into the molding process to be integrated with theplastic body 110 (insert molding), and/or the track can be supplied as aseparate part, for example.

In some examples, a cam lock, set screw, snap, button, spring loadedplunger, ball, or other fastener locks and/or otherwise holds thegraspable area 120 in place at a point along the track. Using thegraspable area 120, a user can adjust a usable height of the ambulationaid 100. Rather than adjusting leg/foot height, a desired heightadjustment can be achieved by manipulation of the graspable area 120along the track.

In some examples, the graspable area 120 and sliding geometry can becombined into one part, which then slides along a track or is fastenedat discrete locations (e.g., threaded inserts that can be unscrewed andscrewed) along the body 110. The combined part can be molded plastic,die cast metal, welded assembly (e.g., metal or plastic), bondedassembly, threaded assembly, etc. In certain examples, rather thansliding along a track, the graspable area 120 can be fastened at one ormore discrete locations along the body 110 via interlocking geometry,threaded fasteners, Velcro™, knob clamp, threaded holes, miter trackstops, etc. As another example, handle height can be adjusted viatelescoping members protruding from the main body 110 that can be lockedinto different heights.

Additionally, handles employed in example ambulation aids may include avariety of grips to facilitate user comfort, durability, and control. Insome examples, a separate grip can be supplied to cover the graspablearea 120 to provide comfort and increased graspability. In someexamples, the graspable area 120 can be implemented as a two-shotinjection molded part in which a grip area is a different (e.g., softer,lower durometer, etc.) material than the rest of the part (e.g., a firstshot of hard plastic and a second shot of rubber).

FIG. 2 illustrates a rear view of the example apparatus 100. As in FIG.1, the example ambulation aid 100 includes a body portion 110, agraspable area 120, and a foot portion 130. As illustrated in theexample of FIG. 2, the graspable area 120 (e.g., a handle) can besituated in a track or other receptacle 140. In certain examples, thereceptacle 140 allows the graspable portion 120 to move. For example,the graspable area 120 can be implemented as a handle that is movablewithin a track 140. The handle can be vertically movable, for example.In other examples, the handle and/or other graspable portion 120 can behorizontally and/or otherwise movable within a track, along a guide,and/or other receptacle 140.

In certain examples, the foot portion 130 can be movable with respect tothe body portion 110 to adjust a height of the body portion 110 withrespect to the ground, floor, or other surface serving as a referenceplane upon which the aid 100 is placed for use. Thus, for example, thegraspable portion 120 and/or the foot portion 130 can be adjusted to a)adjust a height of the aid and/or b) adjust a position of the graspableportion 120 in the body 110 (and thereby with respect to a user).

FIG. 3 depicts the example ambulation aid 100 viewed from a side. As inFIGS. 1-2, the example cane-type ambulation aid 100 of FIG. 3 includes abody portion 110, a graspable area 120, and a foot portion 130. Thegraspable area 120 can reside in and/or otherwise be attached to areceptacle 140 allowing a position (e.g., a height) of the graspablearea 120 to be adjusted with respect to the body portion 110 (andthereby also with respect to a height of a user of the aid 100). Thus,the example cane-type ambulation aid 100 shown in FIG. 3 can be used bya variety of people of a variety of sizes comfortably and easily usingthe adjustable handle and/or other graspable area 120.

Additionally, FIG. 4 shows a front view of the example ambulation aid100. As shown in the example, the body portion 110 and foot portion 130of the cane- or staff-type ambulation aid are visible when viewed from afront view.

FIG. 5 shows an example perspective view of the cane-type ambulation aid100. As illustrated in the example of FIG. 5, a handle-type graspablearea 120 is moveable along with and/or with respect to a channel and/orother receptacle 140 housed in a body portion 110 of the aid 100. Thegraspable area 120 is movable within and/or with respect to thereceptacle 140 to adjust a graspable height of the aid 100 with respectto a user, for example. A foot portion 130 helps provide traction,stabilization, etc., during use of the example aid 100 by a user, forexample.

FIGS. 6-9 illustrate views of an example crutch-type ambulation aid 200.As illustrated in the examples of FIGS. 6-9, while formed from amonocoque, unibody, and/or other similar design, the examplecrutch-style ambulation aid 200 provides an adaptable, adjustable, easyto use and maintain assistant for a user who needs or desires an aid forwalking, standing, etc.

As shown in the example of FIG. 6, the example crutch-style ambulationaid 200 includes a body portion 210 (e.g., a monocoque, unibody,body-on-frame, and/or other construction body), a plurality of graspableareas 220, 225, and a foot portion 230. For example, the crutch-styleambulation aid 200 shown in FIG. 6 includes a single body portion 210 towhich a foot 230 (e.g., a rubber pad, plastic pad, etc.) is attached. Ahandle and/or other graspable portion 220 protrudes from the body 210 inthe example apparatus 200. FIG. 6 illustrates a side or profile view ofthe example apparatus 200.

The body 210 of the example ambulation aid 200 shown in FIG. 6 can bemanufactured from a molded material such as a polymer-based materialformed in unibody or monocoque construction (e.g., hollow, foam-filled,etc.) to provide a lightweight, yet strong, and customizable support fora user, such as an elderly user, rehabbing patient, disabled user, obeseuser, etc.

The body 210 can be formed by a variety of manufacturing processesincluding a twin sheet thermoforming process. In certain examples, thebody 210 can include and/or be formed from material includingtransparent, translucent, antimicrobial, bullet resistant, and/or othermaterial. The body 210 can be provided with one or more customizablefinishes (e.g., laminate, co-extruded laminate, paint, plating,texturing, applied graphics, embedded color/finish in base material,etc.), for example.

In certain examples, the body 210 serves as an enclosure, frame,support, and cosmetic exterior for the ambulation aid 200 to provide arigid structure to the aid 200. In some examples, the body 210 mayinclude openings, compartments, attachment points, interlockingconfigurations, etc., to facilitate incorporation and/or otherattachment of accessories, components, and/or other subassemblies withand/or into the body 210. Depending upon size and configuration, one ormore accessories/components/subassemblies can be formed as part of thebody 210, separate from and attached to the body 210, and/or provided bya third party and accommodated by forming openings and/or otherattachment points in the body 210, for example.

The body 210 and associated components are formed from one or moreselected materials. Material selected to form the body 210 and/or othercomponent(s) may be selected based on one or more factors includingstrength (e.g., tensile strength), density (e.g., lightweight), strengthto weight ratio, Young's modulus, weather resistance, antimicrobialproperties, cleaning ability, bullet resistance, formability, finishing,recyclability, tooling costs, design flexibility, manufacturing cost,reproducibility, etc. Material selection may also depend on and/or beinfluenced by aesthetics including color, transparency, translucency,durometer, surface finish, etc.

In certain examples, the body 210 is formed as a single integral part.For example, the body 210 is formed as a single, complete unit. By beingintegrally formed, the body 210 is structurally stronger thanconventional multi-part constructed frames (e.g., traditional canes thatinclude parts that are fastened together). Further, unlike conventionaldevices that include seams between component parts, the example body 210has a substantially seamless appearance. Construction of a mobility aidfrom substantially fewer parts provides benefits for a stable feel andmanufacturing efficiency (e.g., faster throughput due to less assembly,fewer hand touches, etc.), for example. Fewer connected parts and lessplay in their connections results in less rattling and a moresecure/stable body 210, for example. Additionally, by forming the body210 as a single integral part, weather resistance, water resistance,recyclability, etc., is improved.

In certain examples, the body 210 provides support to a user whilelending strength and stability to the user via the body 210 as well asto connected components such as handle 220, 225, foot 230, etc. Further,the body 210 provides an aesthetically pleasing look by forming part ofan ornamental appearance of the ambulation aid 200.

The graspable areas 220, 225 provide support to a user to grip and holdonto the aid 200. In certain examples, rather than protruding handles220, 225, one or more openings in the body panel 210 and/or other gripson or in the body panel 210 can be provided. In certain examples, thefoot portion 230 can include a skid, ski, tread, etc., instead of or inaddition to a foot post, pad, peg, metallic cleat, etc., to facilitatestability and movement of the aid 200 while supporting the user.

In some examples, the graspable areas 220, 225 can be implemented as apost or pole graspable by a user for support and/or mobility. Thegraspable areas 220, 225 can be molded from plastic, die-cast metal,extruded plastic and/or metal, etc. The graspable areas 220, 225 can beintegrated into the body 210 design. In certain examples, different sizemobility aids can be produced with a fixed and/or movable handle.

In some examples, one or more of the graspable areas 220, 225 (e.g., ahandle) are positioned in a T-slot track (e.g., mounted on or includinga T-slot nut or other connector that slides in a T-slot track) such thatthe graspable portions 220, 225 slide up and down in the T-slot track(also illustrated, for example, in FIGS. 7-9). The track can be designedinto the main body 210 geometry, a separate channel (e.g., metal,plastic, other polymer, etc.) can be inserted into the molding processto be integrated with the plastic body 210 (insert molding), and/or thetrack can be supplied as a separate part, for example.

In some examples, a cam lock, set screw, snap, button, spring loadedplunger, ball, or other fastener locks and/or otherwise holds thegraspable areas 220, 225 in place at a point along the track. Using thegraspable areas 220, 225, a user can adjust a usable height of theambulation aid 200. Rather than adjusting leg/foot height, a desiredheight adjustment can be achieved by manipulation of the graspable areas220, 225 along the track.

In some examples, the graspable areas 220, 225 and sliding geometry canbe combined into one part, which then slides along a track or isfastened at discrete locations (e.g., threaded inserts that can beunscrewed and screwed) along the body 210. The combined part can bemolded plastic, die cast metal, welded assembly (e.g., metal orplastic), bonded assembly, threaded assembly, etc. In certain examples,rather than sliding along a track, the graspable areas 220, 225 can befastened at one or more discrete locations along the body 210 viainterlocking geometry, threaded fasteners, Velcro™, knob clamp, threadedholes, miter track stops, etc. As another example, handle height can beadjusted via telescoping members protruding from the main body 210 thatcan be locked into different heights.

Additionally, handles employed in example ambulation aids may include avariety of grips to facilitate user comfort, durability, and control. Insome examples, separate grips can be supplied to cover the graspableareas 220, 225 to provide comfort and increased graspability. In someexamples, each of the graspable areas 220, 225 can be implemented as atwo-shot injection molded part in which a grip area is a different(e.g., softer, lower durometer, etc.) material than the rest of the part(e.g., a first shot of hard plastic and a second shot of rubber).

FIG. 7 illustrates a rear view of an example crutch-style ambulation aid200 including a body portion 210, graspable areas 220, 225, and a footportion 230. As illustrated in the example of FIG. 7, the graspableareas 220, 225 (e.g., handles) can be situated in a track or otherreceptacle 240. In certain examples, the receptacle 240 allows thegraspable portions 220, 225 to move. For example, one or more of thegraspable areas 220, 225 can be implemented as a handle that is movablewithin a track 240. The handle 220, 225 can be vertically movable, forexample. In other examples, the handle and/or other graspable portion(s)220, 225 can be horizontally and/or otherwise movable within a track,along a guide, and/or other receptacle 240.

In certain examples, the foot portion 230 can be movable with respect tothe body portion 210 to adjust a height of the body portion 210 withrespect to the ground, floor, or other surface serving as a referenceplane upon which the aid 200 is placed for use. Thus, for example, oneor more of the graspable portions 220, 225 and/or the foot portion 230can be adjusted to a) adjust a height of the aid and/or b) adjust aposition of the graspable portion(s) 220, 225 in the body 210 (andthereby with respect to a user).

FIG. 8 depicts a rear perspective view of the example ambulation aid200. As in FIGS. 6-7, the example crutch-type ambulation aid 200 of FIG.8 includes a body portion 210, a plurality of graspable areas 220, 225,and a foot portion 230. The graspable area(s) 220, 225 can reside inand/or otherwise be attached to a receptacle 240 allowing a position(e.g., a height) of the graspable area(s) 220, 225 to be adjusted withrespect to the body portion 210 (and thereby also with respect to aheight of a user of the aid 200). Thus, the example crutch-typeambulation aid 200 shown in FIG. 8 can be used by a variety of people ofa variety of sizes comfortably and easily using the adjustable handleand/or other graspable area 220, 225.

FIG. 9 shows a further angled view of the example ambulation aid 200. Asillustrated in the example of FIG. 9, one or more of a plurality ofhandle-type graspable areas 220, 225 is moveable along with and/or withrespect to a channel and/or other receptacle 240 housed in a bodyportion 210 of the aid 200. The graspable area(s) 220, 225 are movablewithin and/or with respect to the receptacle 240 to adjust a graspableheight of the aid 200 with respect to a user, for example. A footportion 230 helps provide traction, stabilization, etc., during use ofthe example aid 200 by a user, for example.

FIGS. 10a-c illustrate example handle configurations facilitatingmovement of a handle moveably affixed to a body of an ambulation aid.FIGS. 10a-b illustrate example T-slot configuration for a handle 1010within a track 1020 including a brake mechanism 1015. FIG. 10c shows anexample mechanism to adjust handle height, in which a handle 1030 isheld in place along a track 1040 with one or more sprung pins 1050-1051.The handle 1030 can be attached to a shuttle in the track 1040 and/orcan be combined with a shuttle into one subassembly (e.g., with orwithout an associated braking mechanism). Parts of the handle mechanismcan be manufactured using plastic and/or other extrusion, stamping,and/or forming of sheet material separately and/or as part of the mainbody of the ambulation aid, for example. A slot or hole 1045 is providedin the track 1040 to allow for a cable, guide, and/or other element topass through from one side of the track to another. Concealing a cable,etc., in this way prevents potential snags in use and also adds to theoverall cosmetic appeal of the design, for example. FIG. 10d illustratesan example of a handle 1060 attached to a mounting plate 1070 with aslot 1080 to allow for a cable and/or other element to pass betweenwalls of the ambulation aid and remain hidden from view.

In certain examples, the example ambulation aid 100, 200 includes one ormore areas on and/or in the body 110, 210 by which to provide a decal,logo, picture, and/or other customization. Thus, a decoration,identification, personalization, etc., can be provided by amanufacturer, seller, and/or user in the customizable display area, forexample. The customizable display area may be slightly indented withrespect to the rest of the body 110, 210, for example, to accept customdecals (e.g., flowers, golf, commercial logo (e.g., sports teams,colleges, business, etc.), photos, etc.) and/or other graphic todecorate the ambulation aid 100, 200, for example. In certain examples,the body 110, 210 can include one or more windows, voids, and/or otheropenings to provide access, air flow, accessory fitting, etc. In certainexamples, holes generated to facilitate air flow during forming of thebody 110, 210 can be incorporated into and/or hidden by an opening orother feature in the body 110, 210.

In certain examples, the ambulation aid 100, 200 can also and/oralternatively include an accessory area or mount provided in the body110, 210. The accessory area/mount can be used for a light, reflector,decal, logo, speaker, etc. If the accessory is electronic, a batteryand/or other power source can be, for example, positioned behind theaccessory in the area, otherwise located inside the body 110, 210,and/or attached to the body 110, 210 and/or other attached element, suchas a handle track, handle, tray, seat, storage, etc.

In certain examples, different materials can be used in a manufacturingprocess to provide a range of ambulatory aid products with varyingcharacteristics. Ambulatory aid products can be formed from polymermaterial, metal, fiberglass, etc. For example, high-density polyethylene(HDPE), acrylonitrile butadiene styrene (ABS), ABS with an acrylic cap,acrylic, thermoplastic olefin (TPO), polypropylene (PP), polycarbonate(PC), polyethylene (PE), polyethylene terephthalate (PET), polyethyleneterephthalate glycol-modified (PETG), etc., can be used to form panelsand/or accessory parts of an ambulation aid. Further, laminated filmsand/or other printed graphics, screen printed, pad printed, etched,textured, etc., can provide decorative effects (e.g., carbon fiber,brushed metal, wood grain, logos (e.g., sports team, etc.), photos,etc.) applied, co-extruded, co-cast, etc., to a plastic substrate, suchan ABS or TPO substrate, with or without an acrylic over cap layer. Incertain examples, the interior and exterior can be different colors andmaterials, such as having a glossy metallic exterior material and atextured or soft touch, leather-like material on the interior. Acrylic,PC, PP, PET, PEG, RPET, or the like can be used to create a clear part.Using thermoplastics, such as HDPE, TPO, PP, PE, PET, PETG, etc.,enables portions of the body to be formed as a living hinge, includingan ability to mold the tray and/or the seat as part of the main bodyusing a living hinge configuration, for example. Alternatively,components such as the seat, tray, etc., can be molded separately andattached with a separate hinge, for example.

In certain examples, an ambulation aid is constructed using a polymermaterial to create a hollow, structurally stable panel or set of panels.Such construction can be accomplished in a single step by manufacturingprocesses such as, but not limited to, rotational molding, blow molding,injection molding (e.g., with or without a foaming agent), gas assistedinjection molding (e.g., with or without a foaming agent), extrusion, ortwin sheet thermoforming. Alternatively or additionally, two or moreseparate parts can be created and later joined together to create ahollow part. The separate parts can be created by manufacturingprocesses such as, but not limited to, injection molding, thermoforming,extrusion, slumping, etc. These parts can then be joined by processessuch as, but not limited to, adhesive bonding, chemical welding,ultrasonic welding, snap/interlocking fit, thermal bonding, etc.

In certain examples, part(s) can also be created by laying or sprayingfiberglass type material, carbon fiber, etc. For example, a flat sheetof fiberglass material can be formed into a part and/or ambulation aidstructure, for example. Chopped fiberglass can be sprayed over and/orinto a mold to form a part. A composite material can be created byspraying and/or laying up fiberglass onto/into another shell material(e.g., formed plastic or other polymer, etc.) for added structuralintegrity. Additionally, part(s) can be stamped out of metal and welded,brazed, soldered, mechanically fastened, interlocking/snap fit, and/orglued together, for example. In certain examples, lost core (e.g., sand,wax, etc.) casting methods can be used to create a hollow metal part.Die cast part(s) can also be created. In certain examples, inflatablepart(s) can be formed.

In certain examples, a filler, such as foam, can be inserted in a hollowshell to provide additional support. In certain examples, a solid formsuch as solid foam can be formed (e.g., machined) and skinned forappearance and/or structure. A foaming agent can be used with injectionmolding to create a semi-hollow/hollow part, for example,

In certain examples, one or more snap-on type covers can be added over aframe to provide an ambulation aid or component part(s). For example, apanel, wrap, etc., can be snapped or otherwise affixed onto a frame toprovide an ambulation aid. Panels can provide support, decoration, etc.In certain examples, panels can be used to create a body-on-frame,unibody, or unitary design, for example.

In certain examples, a cover can be stretched over a frame, instead ofor in addition to being snapped on. Alternatively or in addition, acover can be slipped over a frame. Covers can also attach to each other,inside and outside, versus attaching to a frame.

For example, foam (e.g., light but rigid foam) can be injected into ahollow polymer body to help support the hollow body. Inserted foam canadd to strength of the body (e.g., for a bariatric version of anambulation aid to support 500 lbs). Foam insertion can be done as partof twin sheet thermoforming or after the part has been thermoformed. Insome examples, a honeycomb or lattice (e.g., cardboard honeycomb soakedin resin) can be used as an insert into a hollow body to add strength tothe hollow part.

Additional strength can also be provided via additional insertedstructural elements (e.g., metal, plastic, fiberglass, etc.), internaland/or external to the body, for example. In certain examples, ribbingand/or other features aside from kiss offs/near kiss offs can beprovided in the design of the monocoque ambulation aid structure to helpprovide strength and stability.

In certain examples, an ambulation aid includes various opportunities to“kiss off,” where two pieces of material (e.g., plastic or otherpolymer) come together to form the part. For example, a kiss off caninclude a mating of walls of the aid for additional strength andstability. A “near kiss” represents where the two walls are almostmating but not quite, which alleviates issues with witness marksaffecting appearance. Based on ornamental surface lines and functionalseams and openings in the body 110, 210 and/or other portion of the aid100, 200, kiss off points can be minimized or hidden so as not todistract from the aesthetic appearance of the ambulation aid.

In an example, an outside mold and an inside mold are used to form twosheets of plastic, which are then pushed together to create the integralpart (e.g., the mobility aid or walker body panel). As opposed totubular metal or PVC, such molding and forming provides a hollow,structurally sound, and adaptable unibody/integral monocoque part forthe mobility aid, while maintaining a lighter weight.

Example Methods of Manufacture

FIG. 11 illustrates a flow diagram of an example method 1100 tomanufacture an ambulation aid. At block 1110, parameters for design ofan ambulation aid are entered. For example, a process can be selectedand configured for thermoforming, blow molding, injection molding,slumping, etc. Parameters regarding shape, thickness, spacing,accessory(-ies), color, texture, other customization, etc., can also bespecified. Parameters may be used to configure a machine and/or processfor manufacture of one or more part(s) of the ambulation aid. Initialinput parameters and customization for a particular design can beprovided for the manufacturing process.

At block 1120, one or more parts of the body of the ambulation aid arecreated using a configured manufacturing machine and/or process. Forexample, using a forming process such as thermoforming (e.g., twin sheetthermoforming), blow molding, rotational molding (also referred to asrotomolding), etc.). In twin sheet thermoforming, for example, twosheets of material are first formed and then fused to form an integralbody for the ambulation aid. In blow molding or rotational molding,material is provided into a mold and then formed into an integral bodyfor the ambulation aid, for example.

At block 1130, the process determines whether one or more subassembliesare to be included. If so, then, at block 1135, one or more accessorypart(s) are attached to the body. For example, one or more handles,feet, hand straps, clip-on frames, and/or the like can be attached tothe integral body. Attachments can be formed and/or provided aspreviously-formed components to the process, for example.

At block 1140, customization of the ambulation aid is identified. Forexample, a manufacturer, retailer, and/or end user may specifyadditive(s)/treatment(s) such as one or more layers, colors, paints,laminates, metal flakes, graphics, pad printing, screen printing, laseretching, other surface treatment, etc., to be included in the ambulationaid. If so, then, at block 1145, the aid is customized for the user. Forexample, one or more such additive(s)/treatment(s) can be added toand/or otherwise integrated into the ambulation aid. In certainexamples, one or more of such customizations can be provided as part ofthe creating of the integral body. Alternatively or in addition, one ormore of such customizations can be provided as a separate automatedand/or manual process after forming of the integral body.

At block 1150, the aid is made available for use. For example, theambulation aid is made available for use, trial, sale, and so on. Atblock 1160, further user customization can be performed. For example,one or more add-ons, accessories, etc., such as a graphic, grip, foot,etc., can be selected and added/modified with respect to the ambulationaid. For example, further user customization can be performed after userpurchase of the ambulation aid from a retailer, such as a store, and/orby a retailer/wholesaler prior to a sale to an end user.

FIG. 12 illustrates a flow diagram of an example thermoforming process1200 to manufacture an ambulation aid. Thermoforming is a manufacturingprocess in which a plastic sheet is heated to a pliable formingtemperature, formed to a specific shape in a mold, and trimmed to createa usable product. The sheet, or “film”, is heated to a high-enoughtemperature that it can be stretched into or onto a mold and cooled to afinished shape. In heavy gauge thermoforming, discrete sheets ofmaterial are typically fed into a machine for forming. In thin gaugethermoforming, a roll of material is typically provided.

Twin-sheet thermoforming can be performed using single station ormultiple station thermoforming. There are two primary types of singlestation thermoforming, simultaneous forming and sequential forming. Insimultaneous single station thermoforming, two polymer (or othermaterial) sheets are formed simultaneously. In sequential single stationthermoforming, the two sheets are formed sequentially. In multiplestation thermoforming, the sheets are heated as well as formedsequentially before being forced together. Either of these processes canbe used, but multiple station thermoforming provides advantages such asbeing able to utilize different thicknesses of the two sheets ofmaterials, different types of materials, and better overall control ofthe process as each sheet is processed independently prior to fusingthem together, for example. Using a single-station process, however,involves less expensive equipment and a simpler process of operation.

Both single and multiple station twin-sheet thermoforming include thesame basic elements, as shown in the example of FIG. 12. At block 1210,two sheets of material (e.g., plastic or other polymer, etc.) are loadedinto their respective holding frames. In single station thermoforming,the two sheets of material are loaded simultaneously into theirrespective holding frames. The holding frame(s) can include a onedual-sheet frame that holds both sheets for simultaneous type singlestation forming, or two individual frames for sequential type singlestation forming, for example. In multiple station thermoforming, thesheets are loaded sequentially into their respective holding frames.

At block 1220, sheets are heated to their forming temperature. In singlestation thermoforming, the two sheets of material are heated to formingtemperature simultaneously in their respective holding frames. Inmultiple station thermoforming, the sheets are heated to formingtemperature sequentially in their respective holding frame(s).

At block 1230, sheets are positioned with respect to their correspondingmold. For example, a first sheet is brought over a mold and a secondsheet is brought under a mold. If the process is a single stationsimultaneous type process, the first and second sheets are positionedwith respect to first and second molds simultaneously (including, asused herein, substantially simultaneous given some system and/or processdelay). If the process is a single station sequential type process, thefirst and second sheets are positioned with respect to first and secondmolds sequentially. If the process is a multiple station process, thesheets are positioned with respect to first and second moldssequentially.

At block 1240, the heated sheets are formed to their respective moldsand then forced together to fuse into an integral part. For example, insingle station simultaneous thermoforming, vacuum is applied to bothmolds simultaneously to form the parts and then the two molds closetogether. In some examples, pressure may also be applied to the sealedchamber inside the part to help form the sheets.

In sequential type single station thermoforming process, a first heatedsheet is formed to a bottom mold with vacuum and/or pressure. The firstsheet is released from a thermoforming machine frame, and the bottommold drops out of the way. Then, a second heated sheet shuttles orrotates under its respective mold. Vacuum and/or pressure is thenapplied to form the second sheet to the top mold. Subsequently, theframe holding the second sheet drops out of the way, and the two moldsare forced together fusing the two sheets into one integral part.

In a multiple station process, each sheet is heated and formedsequentially. Subsequently, the two molds holding the two formed sheetsare forced together, while the sheet material is still hot, to fuse thetwo parts together into an integral part. For example, a first sheet isloaded into a holding frame. Then, that first sheet is moved into aheating station. After the first sheet has moved into the heatingstation, a second sheet is loaded into a second holding frame. After thefirst sheet has heated sufficiently to forming temperature, the firstsheet progresses to a forming station over or under its respective mold.At this point the second sheet now progresses to the heating station.The first sheet is formed to its respective mold via vacuum and/orpressure. At this point the second sheet progresses from the heatingstation over/under its respective mold. Then, the second sheet is formedto its respective mold via vacuum and/or pressure. At this stage, thetwo molds are forced together to fuse the two formed sheets into anintegral part. The integral part is ejected from the molds and ready forpotential trimming operations.

As discussed above, areas where the two sheets are forced into contactwith each other are commonly referred to as “kiss-offs” and can providemuch increased durability and structural integrity to the formedintegral part. In kiss-off areas, one can typically observe witnessmarks in the plastic and/or other polymer sheet where the respectivemolds have applied pressure to fuse the heated material together. Hidingor disguising these witness marks within the design of the monocoqueambulation aid part can assist in alleviating their detraction from theoverall finished appearance of the part. Areas where the molds cometogether entirely and force all of the heated material out of a givenarea (“pinch-offs”) can result in the trimming of the formed integralpart

Areas where the two sheets just meet up but do not actually fusetogether are commonly referred to as “near kiss-offs.” Near kiss-offscan also provide increased durability and structural integrity, butwithout leaving the witness mark observed with kiss-offs. Near kiss-offscan be implemented in forming an example ambulation aid in place of orin conjunction with the kiss-off features described above, for example.

At block 1250, the formed integral part is ejected from the molds andready for trimming. At block 1260, the formed part can be trimmed.Trimming can be executed by hand manual knife operation, hand router,Computer Numerically Controlled (CNC) router, manual or automated diecutting, etc.

FIG. 13 illustrates a flow diagram of an example blow molding process1300 to manufacture an ambulation aid. Blow molding is a manufacturingprocess by which hollow plastic parts are formed.

At block 1310, polymer material is heated to melt the polymer materialinto a mold. In certain examples, the blow molding process begins withmelting down plastic and forming the plastic into a parison or preform.The parison is a tube-like piece of plastic with a hole in one endthrough which compressed air can pass. The parison can be of a singlematerial type, or the parison can be multiple layers to create a desiredoutside aesthetic, for example, or other varying property(-ies). Theparison is then heated.

At block 1320, the heated material is inflated in the mold. For example,the heated parison is clamped into a mold, and air is pumped into theparison. The air pressure pushes out (e.g., inflates) the material(e.g., plastic or other polymer) to match the mold. At block 1330, theinflated material is cooled.

At block 1340, once the material has cooled and hardened the mold opensup and the formed part is ejected. At block 1350, the formed part may betrimmed, if necessary or desired.

In general, there are three main types of blow molding: extrusion blowmolding, injection blow molding, and stretch blow molding. In extrusionblow molding (EBM), plastic is melted and extruded into a hollow tube (aparison). The parison is captured by closing the parison into a cooledmetal mold. Air is then blown into the parison, inflating it into theshape of the hollow container or part. After the plastic has cooledsufficiently, the mold is opened and the part is ejected.

Extrusion blow molding can be continuous or intermittent. In continuousextrusion blow molding, the parison is extruded continuously, andindividual parts are cut off with a suitable knife. In intermittentextrusion blow molding there are two processes: straight intermittentand accumulator. The straight intermittent method is similar toinjection molding in which a screw turns, stops, and pushes the meltout. With the accumulator method, an accumulator gathers melted plastic,and, when the previous mold has cooled and enough plastic hasaccumulated, a rod pushes the melted plastic and forms the parison. Inthis case the screw may turn continuously or intermittently.

In injection blow molding (IBM) can be used for the production of hollowobjects. In an IBM process, a polymer is injection molded onto a corepin; then the core pin is rotated to a blow molding station to beinflated and cooled. The IBM process is divided into three elements:injection, blowing and ejection.

An injection blow molding machine is based on an extruder barrel andscrew assembly which melts the polymer. The molten polymer is fed into ahot runner manifold where it is injected through nozzles into a hollow,heated preform mold. The preform mold forms the external shape and isclamped around a mandrel (the core rod) which forms the internal shapeof the preform. The preform includes a fully formed bottle/jar neck witha thick tube of polymer attached, which will form the body.

The preform mold opens and the core rod is rotated and clamped into thehollow, chilled blow mold. The core rod opens and allows compressed airinto the preform, which inflates it to the finished article shape.

After a cooling period the blow mold opens and the core rod is rotatedto the ejection position. The finished article is stripped off the corerod and leak-tested prior to packing. The preform and blow mold can havemany cavities, typically three to sixteen depending on the article sizeand the required output. There are three sets of core rods, which allowconcurrent preform injection, blow molding and ejection, for example.

In a stretch blow molding (SBM) process, the polymer is first moldedinto a “preform” using the injection molding process. The preforms arepackaged, and fed (after cooling) into a reheat stretch blow moldingmachine. In the SBM process, the preforms are heated (e.g., usinginfrared heaters) above a transition temperature, and then blown usinghigh pressure air into an integral part (e.g., an integral ambulationaid body part) using metal blow molds. The stretching of some polymers,such as PET (polyethylene terephthalate) results in strain hardening ofthe resin, allowing the formed parts to resist deforming under thepressure.

FIG. 14 illustrates a flow diagram of an example rotational moldingprocess 1400 to manufacture an ambulation aid. Rotational molding (alsoreferred to as rotomolding) involves a hollow mold which, at block 1410,is filled with a charge or shot weight of material. At block 1420, themold is then slowly rotated (e.g., around two perpendicular axes)causing the softened material to disperse and stick to the walls of themold. For example, the mold is rotated to tumble/spin the materialaround to evenly coat the mold.

At block 1430, the mold is cooled. For example, the polymer is to becooled so that it solidifies and can be handled safely. The part shrinkson cooling, coming away from the mold and facilitating easy removal ofthe part. The cooling rate must be kept within a certain range. Rapidcooling (for example, water spray) may result in cooling and shrinkingat an uncontrolled rate, producing a warped part. In order to maintaineven thickness throughout the part, the mold continues to rotate at alltimes during a heating phase and, to avoid sagging or deformation, alsorotates during a cooling phase. At block 1440, the part is removed fromthe mold. At block 1450, the formed part may be trimmed if needed ordesired.

In certain examples, a gas assist molding process can be used tomanufacture an example ambulation aid and/or component thereof. Anexample gas assist molding process includes injecting a fixed, shortvolume of polymer melt into a vented mold cavity (e.g., a “short shot”).Gas channels act as internal runners along the part to fill from asingle gate into the mold, thereby eliminating weld lines in theresulting part associated with multiple gates. After polymer injection(or after a short delay), compressed gas (e.g., nitrogen and/or otherrelatively inert gas) is injected into the mold cavity through a centralcore of the melt. The gas pressure acts on the fluid melt core,completing the mold filling process. The gas takes a path of leastresistance, penetrating and hollowing (e.g., coring out) a network ofpredesigned thick flow leader sections (e.g., gas channels), displacingmolten polymer at the core, and filling out the mold cavity (e.g.,primary gas penetration). Packing is not accomplished by an injectionram/cushion, but rather by the gas pressure itself. After mold filling,the gas pressure is maintained in order to pack the part and compensatefor volumetric shrinkage (e.g., secondary gas penetration). After thepart has cooled to a point at which the part is rigid enough to eject,the gas is vented off through a pin or by sprue breakaway (and sometimesrecycled) prior to mold opening and part ejection, for example.

In operation, an elderly, ill, injured, or impaired individual uses anambulation aid to assist that user in moving around, standing,supporting themselves, rehabilitation, etc. The user grasps thehandle(s) of the device to help him or her walk forward, turn,stabilize, stand, etc. Based on the design, weighting, and arrangementof the ambulation aid, the aid may be self-supporting and can remainstanding upright when not in use.

Modifications and variations as would be apparent to a skilled addresseeare determined to be within the scope of the present invention.

It is to be understood that, if any prior art is referred to herein,such reference does not constitute an admission that the prior art formsa part of the common general knowledge of the art in any country.

It will be appreciated by persons skilled in the art that numerousvariations and/or modifications may be made to the invention as shown inthe specific embodiments without departing from the spirit or scope ofthe invention as broadly described. The present embodiments are,therefore, to be considered in all respects as illustrative and notrestrictive.

Several embodiments are described above with reference to the drawings.These drawings illustrate certain details of specific embodiments thatimplement the systems and methods and programs of the present invention.However, describing the invention with drawings should not be construedas imposing on the invention any limitations associated with featuresshown in the drawings. It will be understood that the inventiondisclosed and defined in this specification extends to all alternativecombinations of two or more of the individual features mentioned orevident from the text or drawings. All of these different combinationsconstitute various alternative aspects of the invention.

1. A method of forming a single-point supportive ambulation aid as anintegral part, the method comprising: providing a supply of moldablefoam material; and forming, from the supply of moldable foam material,the ambulation aid as an integral part, the integral part including asingle body portion formed from the moldable foam material to support auser, wherein the single body portion is formed to attach to: a) agraspable area including a sliding geometry integrated proximate to afirst end with a side of the body portion and protruding from the bodyportion and providing an area to be gripped by a user outside the bodyportion, the graspable area protruding from a receptacle formed in thebody portion and having a position adjustable within the receptacle viathe sliding geometry, the receptacle located in an upper area of thebody portion and including a track to facilitate movement of thegraspable area within the receptacle via the sliding geometry; and b) afoot portion integrated with the body portion and providing a singlepoint of contact with a walking surface to facilitate user movement andsupport in conjunction with the body portion and graspable area throughthe integral part, the foot portion located in a bottom area of the bodyportion, wherein the foot portion contacts the walking surface in adirection of force substantially perpendicular to the walking surfaceand wherein the graspable area protrudes from the body portionsubstantially perpendicular to the foot portion.
 2. The method of claim1, wherein the aid is formed as a cane-type ambulation aid having asingle graspable area.
 3. The method of claim 1, wherein the aid isformed as a crutch-type ambulation aid having a plurality of graspableareas.
 4. The method of claim 3, wherein at least one of the pluralityof graspable areas is formed as an adjustable handle positioned in aT-slot track.
 5. The method of claim 1, wherein the graspable area isformed to include a movable component to adjust a height of the bodyportion with respect to the user.
 6. The method of claim 1, wherein thegraspable area is formed as a handle.
 7. The method of claim 1, whereinthe integral part is formed in monocoque construction.
 8. The method ofclaim 7, wherein a skin forming a surface of the integral part providesa supporting structure to provide support for the user via the integralpart.
 9. The method of claim 1, wherein the foot portion is formed as amovable component to adjust a height of the body portion with respect tothe walking surface.
 10. A single-point supportive ambulation aidcomprising: a means for support formed from moldable foam material in asingle body portion to support a user; a means for grasping integratedproximate to a first end with and protruding from the means for supportand providing an area to be gripped by a user outside the means forsupport, the means for grasping protruding from a means for receivingformed in the means for support and having a position adjustable withinthe means for receiving; and a means for contacting a walking surfaceintegrated with the means for support and providing a single point ofcontact with the walking surface to facilitate user movement and supportin conjunction with the means for support and means for grasping. 11.The ambulation aid of claim 10, wherein the aid is formed as a cane-typeambulation aid having a single graspable area.
 12. The ambulation aid ofclaim 10, wherein the aid is formed as a crutch-type ambulation aidhaving a plurality of graspable areas.
 13. The ambulation aid of claim12, wherein the means for grasping is formed as an adjustable handlepositioned in a T-slot track.
 14. The ambulation aid of claim 10,wherein the means for grasping is formed to include a movable componentto adjust a height of the body portion with respect to the user.
 15. Theambulation aid of claim 10, wherein the means for grasping is formed asa handle.
 16. The ambulation aid of claim 10, wherein the means forsupport is formed in monocoque construction.
 17. The ambulation aid ofclaim 16, wherein the means for support further includes a skin forminga surface of the single body portion and providing a supportingstructure to provide support for the user via the single body portion.18. The ambulation aid of claim 10, wherein the means for contacting awalking surface is formed as a movable component to adjust a height ofthe body portion with respect to the walking surface.